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Using 3d Printed Molds for Constructing Topology Optimized Concrete Dams

Khatami, Alireza | 2023

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  1. Type of Document: M.Sc. Thesis
  2. Language: Farsi
  3. Document No: 56407 (09)
  4. University: Sharif University of Technology
  5. Department: Civil Engineering
  6. Advisor(s): Khaloo, Alireza
  7. Abstract:
  8. In this research, a new method is proposed for constructing concrete structures with complex geometry, including topology-optimized concrete dams on a small scale. According to global statistics, concrete is the most consumed material in the world after water, and its production process causes a lot of damage to the environment. One of the best ways to reduce concrete consumption is to use tools such as topology optimization to design concrete structures. Nevertheless, few research has been done in the field of topology optimization of concrete dams, one of the important reasons for which is the difficulty of building physical model to perform physical tests, validating numerical models, and accurately understanding their behavior; Because the topology optimization method often leads to complex geometries, and fabricating formworks manually is expensive and time-consuming. In a higher perspective, this problem exists in all concrete structures with complex geometry. In this research, a new method called thin 3D printed formworks reinforced with thatch is proposed for constructing them. In this method, the formwork of the concrete structure with very low thickness is 3D printed and after reinforcing it with thatch, concrete pouring is done. After the concrete hardens, the thatch is washed and the 3D printed formwork is removed from the concrete structure with the help of a hair dryer and scissors. In this research, in the first step, two rectangular cube samples were built with a thin 3D printed formwork, one of which was reinforced with thatch. The results of this experiment showed the effectiveness of the proposed method to strengthen the thin formwork. After proving the efficiency of the method, two concrete gravity and double-arch dams with optimized topology were built with it. Then, by building a cross-shaped tubular sample, the efficiency of this method was determined in comparison with the water/sand method. Also, the proposed method can be widely used in the construction industry to build concrete structures with complex geometry. To prove this, the construction of a decorative concrete capital with complex geometry was done by the mentioned method. At the end, the experiences gained during the development of this method are stated for the researchers
  9. Keywords:
  10. Topology Optimization ; Mold ; Three Dimentional Printing ; Double-Arch Concrete Dam ; Gravity Dam ; Concrete Dam

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